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Aggregate Quality Control/Quality Assurance Program January 13, 2016 A joint effort of the North Carolina Department of Transportation and the North Carolina Aggregates Association

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Page 1: Aggregate Quality Control/Quality Assurance Program · PDF fileAggregate Quality Control/Quality Assurance Program ... The Aggregate Quality Control/Quality Assurance Program is designed

Aggregate

Quality Control/Quality Assurance

Program

January 13, 2016

A joint effort of the

North Carolina Department of Transportation

and the

North Carolina Aggregates Association

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TABLE OF CONTENTS

I. GENERAL DESCRIPTION ................................................................................................................ 1

II. PROGRAM REQUIREMENTS .......................................................................................................... 2 A. Basic Requirements ............................................................................................................................ 2

B. Quality Control Plan ........................................................................................................................... 2

C. Certified Laboratory ............................................................................................................................ 3

D. Quality Control Technician ................................................................................................................. 3

E. Plant Approval Process ........................................................................................................................ 3

F. Certification for Participation in the Aggregate QC/QA Program ...................................................... 4

III. AGGREGATE SAMPLING AND TESTING PROCEDURES .................................................................. 5 A. Producer's Quality Control ................................................................................................................... 5

B. NCDOT Verification and QA Split Sampling .................................................................................... 7

C. Roadway Assurance/Acceptance and Independent Assurance ............................................................ 9

IV. EXHIBITS .................................................................................................................................. 11 EXHIBIT A- NCDOT AGGREGATE QC/QA PLANT OWNERSHIP UPDATE FORM..................................... 13

EXHIBIT B- TESTING EQUIPMENT LIST ................................................................................................... 15

EXHIBIT C- SAMPLING PROCEDURES ...................................................................................................... 17

EXHIBIT D- PROCEDURES FOR SPLITTING AND LABELING SAMPLES ...................................................... 20

EXHIBIT E- RAPID DRYING PROCEDURE ................................................................................................. 24

EXHIBIT F- QAP SYSTEM FOR REPORTING SAMPLE TEST DATA AND RETRIEVING STATISTICS ............ 26

EXHIBIT G- TOLERANCES FOR COMPARISONS OF QC/QA GRADATIONS ............................................... 29

EXHIBIT H- INDEPENDENT ASSURANCE SAMPLING AND TESTING ......................................................... 32

EXHIBIT I - SPECIFICATIONS (GRADATIONS, LL, and PI) ....................................................................... 34

EXHIBIT J- PROJECT CONSTRUCTION OF APPROVED STOCKPILES (ABC- TYPE B) ................................ 39

EXHIBIT K- INVESTIGATION PROCEDURES FOR FAILING ROADWAY ASSURANCE SAMPLES ................. 43

EXHIBIT L- FIELD PROCEDURE FOR INVESTIGATION OF ROADWAY ASSURANCE FAILURE FOR

GEOMATERIALS LAB FIELD ENGINEER ................................................................................................... 44

EXHIBIT M AGGREGATE QC/QA SAMPLING AND TESTING TRAINING MANUAL ................................... 46

EXHIBIT N QC/QA PROGRAM CONTACT INFORMATION ........................................................................ 82

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I. GENERAL DESCRIPTION

The Aggregate Quality Control/Quality Assurance Program is designed to give aggregate

producers more responsibility for controlling the quality of material they produce and to utilize

the quality control information they provide in the acceptance process by the North Carolina

Department of Transportation (NCDOT). It requires aggregate producers to perform quality

control sampling, testing and record keeping on aggregates they ship for use by the Department.

Also, it requires the Department to perform quality assurance and verification sampling, testing

and record keeping to confirm the performance of the producers' control plan as set forth herein.

This program is designed for Aggregate Producers providing Clean Coarse or Fine Aggregates

for use on or in products such as asphalt, concrete, block, etc., and when providing any type of

aggregate base material, including cement treated base that is utilized on any type of NCDOT

Maintenance or Contract Project whether purchased by a Contractor or sold directly to the

Department for use on any current NCDOT right of way. Asphalt sand that is produced by and

utilized by the same asphalt producer shall be tested according to the provisions of the Hot Mix

Asphalt Quality Management System Manual.

It is the intent of this program that acceptance or rejection of material be based on the total

program. Therefore, a comparison of the Quality Control, Quality Assurance, Verification, and

other sample data may be used by the Department for acceptance or rejection of a lot of material.

Participation in this program does not relieve the producer of the responsibility of complying

with all requirements of the NCDOT Standard Specifications for Roads and Structures.

This manual contains information regarding the sampling and testing of material at the Aggregate

Producer’s facility (quarry, sand pit, sales yard, etc.). Sampling and testing requirements at other

locations (including but not limited to: present NCDOT right of way, asphalt, concrete, pipe, or

block plants) may be found in other publications such as the Aggregate Sampling Manual or the

Hot Mix Asphalt Quality Management System Manual.

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II. PROGRAM REQUIREMENTS

A. Basic Requirements

There are four basic requirements for approval to participate in either Section.

The source must be on the NCDOT Aggregate Physical Properties List.

The facility must have an approved in-house quality control plan.

The facility must have a certified laboratory or have written approval to use an off-site

certified laboratory.

The facility must have a NCDOT certified quality control technician.

B. Quality Control Plan

The Producer must prepare a written quality control plan. The plan may be generic, but must be

site specific. The plan must indicate in detail how the Producer proposes to control the

equipment, materials, and production methods to insure that the specified products are obtained.

The plan must list the personnel responsible for production and quality control at the site and

include information on how to contact each person. The following specific information must

also be included in the plan:

Identification of the physical location of the source, to include a description of the property

site and reference to the nearest identifiable points such as highways and towns.

A description of the signs used to identify each stockpile as intended for NCDOT usage.

Stockpile signs must be legible from the cab of a truck fifty feet from the identified pile.

A loading and shipping control plan which includes a description of the methods by which

the products are to be loaded and shipped for use by the Department, including safeguards

against loading improper aggregate, contamination, degradation, and segregation of the

aggregate. The plan must also include methods of insuring that all products are accurately

identified and that all shipping units are clean.

A plan for dealing with quality control sample failures. This plan must include how the

Producer plans to initiate an immediate investigation and how the Producer will implement

corrective action to remedy the cause of the problem.

Two copies of the Producer's written quality control plan must be submitted with the original

request for plant approval. Two copies of an updated Plant QC Plan must be submitted when

changes are made to the plant’s operations or ownership. A copy of the Plant’s Ownership

Update Form must be submitted by December 31st of each year or when there is a change to the

plant’s ownership. An example of the Plant Ownership Update Form may be found in Exhibit A.

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C. Certified Laboratory

The Program requires all tests to be conducted at laboratories certified by the Department. It is

expected that each source, including distribution yards, will establish and maintain its own

laboratory for the performance of quality control testing, but the Department will consider a

producer's request to utilize a certified laboratory in the same general vicinity. The Producer

must make this request in writing and have written approval, from the Department, before testing

aggregates off site. The equipment required for a certified laboratory is listed in Exhibit B.

Records on instrument calibration and maintenance and sample collection and analysis must be

maintained at the laboratory. The Department may require a demonstration of the equipment. A

list of equipment can be found in Exhibit B.

D. Quality Control Technician

All samples must be taken and tested by quality control technicians certified by the Department.

The Producer must designate and identify the quality control technicians responsible at each

plant. It is imperative that NCDOT sampling and testing procedures be followed and that

NCDOT approved equipment be used in order to reduce the number of possible causes of

differences between the producer's quality control results and the Department's quality assurance

results.

Quality control technicians may be certified as NCDOT Aggregate QC/QA Sampling

Technicians or as NCDOT Aggregate QC/QA Sampling and Testing Technicians. NCDOT

QC/QA Sampling Technicians are authorized to take samples of materials, NCDOT Aggregate

QC/QA Sampling and Testing Technicians are authorized to both sample and test materials.

At least one certified technician, either a NCDOT Aggregate QC/QA Sampling Technician or a

NCDOT Aggregate QC/QA Sampling and Testing Technician must be on site at all times, unless

prior approval has been granted by the Department for specific circumstances, when material that

may be used on NCDOT Right of Way is being shipped. Technicians actively testing will be

subject to assessments conducted by NCDOT personnel at least annually to insure proper

procedures are followed.

Technicians are subject to loss of certification by revocation. The primary reason for the loss of

a certification by this means would be the falsifying of test results, records, or reports. Other

reasons that might lead to loss of certification include gross negligence or apparent incompetence

on the part of the technician.

E. Plant Approval Process

The approval process requires the Producer to write the State Materials Engineer at NCDOT,

Materials and Tests Unit, 1801 Blue Ridge Road, Raleigh, NC 27607, requesting that the plant

be considered for acceptance into the program. This letter must identify the section(s) under

which the plant would like to operate. It must identify the specific products that are to be

produced. Two copies of the Producer's written quality control plan must be submitted with the

request for approval.

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Prior to plant approval, the Producer shall have produced at least 300 tons of material before it

can be sampled, tested, and added to the NCDOT Aggregate Physical Properties List. A source

must be on the NCDOT Aggregate Physical Properties List before it would be considered for

approval for the QC/QA Program and must meet the general aggregate requirements, including

but not limited to, L. A. Abrasion(AASHTO T96), Sodium Sulfate Soundness (AASHTO T104),

and gradation requirements (AASHTO T11, T27). Fine aggregate must also meet the

requirements of AASHTO T106.

The Department will review the Producer's written quality control plan and if it is approved, an

on-site inspection will be scheduled. This on-site inspection will verify that the Producer's

quality control plan has been implemented and is being followed and that at least one certified

quality control technician is on site and will be present when material is being shipped under this

program. The laboratory will be inspected and certified if it meets the requirements and has not

already been certified. For a list of laboratory equipment required for testing, see Exhibit B. If

either the Producer's quality control plan or laboratory does not meet NCDOT requirements, the

Producer will be informed of the deficiencies in writing. Once the deficiencies have been

addressed, the Producer may again request approval in writing to the State Materials Engineer.

F. Certification for Participation in the Aggregate QC/QA Program

If the Department has approved the Producer's written quality control plan and the on-site

inspection confirms that the program requirements have been met, the Department will issue a

certificate, valid for one year, certifying the plant for participation in the program. At the end of

the year, and each subsequent year, the Department will conduct another on-site inspection and if

all requirements are continuing to be met, the plant will be recertified for participation in the

program for another year. This annual re-inspection of the plant will be scheduled after the

Department has received two copies of the Plant’s updated QC Plan or a completed copy of the

Plant’s ownership update form. Random inspections may be conducted at any time by the

Department to verify compliance with the program requirements.

This certification will authorize the plant to operate under the applicable section(s) of this

program.

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III. AGGREGATE SAMPLING AND TESTING PROCEDURES

Sampling and testing is required when an Aggregate Producer is providing clean coarse

aggregate or fine aggregate to be used in asphalt, concrete, pipe, brick and block, etc. It is also

required when providing any type of aggregate base material, including cement treated base that

is utilized on any type of NCDOT Maintenance or Contract Project whether purchased by a

Contractor or sold directly to the Department. A description of sampling procedures can be

found in Exhibit C.

A. Producer's Quality Control

The Producer's Quality Control (QC) samples are used by the Producer to monitor the quality of

material being shipped. The Producer is to perform all aggregate sampling and testing in

accordance with this manual.

1. Quality Control Sample - These samples are taken by the Producer to monitor the quality of

material being shipped from an approved facility.

2. Lot Size - Lot sizes for aggregates shall be 2,000 tons for each size of material shipped, or a

minimum of one sample per week for each size of material shipped to the Department, whichever

comes first.

3. Sampling - The certified plant technician is to obtain a sample from each lot shipped. QC

samples will consist of one sample per lot. The sample is to be taken from the stockpile,

conveyor belt or other location approved by the Department. Stockpile samples are to be taken

from the same area of the stockpile from which material is being shipped. The minimum sample

sizes for aggregate samples are as follows:

Aggregate Sample Weight Requirements (pounds)

Material Quality Control

Clean Coarse Aggregate 20

Fine Aggregate 10

Aggregate Base Material 35

4. Sample Identification and Record Keeping - It is critical that care be taken to properly label

samples and record test data accurately.

Producer's Quality Control samples are to be identified with consecutive numbers for each size

material and stockpile; QC-1, QC-2, etc. The samples are to be numbered consecutively for the

entire calendar year.

For ABC samples going to an NCDOT project, the QC Sample number is to be recorded by the

Producer on the delivery ticket of the truck loaded immediately after the sample material is

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obtained in order that a RC Sample may be taken from the corresponding area of the roadway if

needed.

All Quality Control test results are to be entered into the Department’s internet based QAP

System within five (5) business days of the sample being obtained.

Quality Control data for each size material is to be retained by the Producer for at least one year

and made available to the Department upon request.

5. Test Procedures - Modifications to standard test procedures are permitted in some cases in this

program. For clean coarse aggregate, no wash test is required on the Producer's split half of the

Quality Control sample unless requested by the Department. For fine aggregate, the wash test,

with rapid drying (see Exhibit E) being allowed, is to be performed on all samples. For ABC

samples, soil mortar testing is required on all samples, see Exhibit M.

6. Check Samples - If the test results for a sample indicate the material does not meet the

specification requirements, a check sample is to be immediately obtained by the Producer. The

check sample is to be doubled in size and taken in the same manner as the original sample. The

sample is to be clearly identified and split with one half tested by the Producer and the other half

provided to the Department.

If the check sample indicates the material meets the specification requirements, the Producer is to

record on the test report form what is felt to be the reason for the original failure and then may

resume normal testing procedures.

If the check sample indicates the material does not meet the specification requirements, the

Producer is to notify the Department. The Producer is to immediately initiate an investigation to

determine the cause of the failure. The investigation is to include a review of the sampling

procedures, the equipment used in the production and the testing of the material, and the testing

procedures of the technician. If the cause can be attributed to one of the above categories, the

Producer is to take corrective action to bring the material, equipment, or procedure into

compliance. The Producer is to then record the corrective action on the test report form and take

another check sample after the corrections have been made. The check sample is to be doubled

in size and taken in the same manner as the original sample. The check sample is to be clearly

identified and split with one half tested by the Producer and the other half provided to the

Department for Quality Assurance (QA) check sample.

If the second check sample indicates the material meets the specification requirements, the

Producer may resume normal testing procedures.

If the second check sample indicates the material does not meet the specification requirements,

the Producer is to notify the Department and stop the shipment of material. The Producer is to

continue the investigation into these failures and work with the Department to determine the

cause.

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All check samples will be identified and follow the previous sample in consecutive order. (i.e.,

QC-7, QC-8, QC-9)

7. Noncompliance – If the Producer has failed to meet the minimum sampling frequencies

described above, the Department will request in writing that the Producer explain the

circumstances related to the incident. The Producer must respond in writing postmarked within

one week of receipt of the request. If the Department finds the response inadequate, the

Department will notify the Producer of the deficiencies and may remove the plant from the

Program. If the Producer does not respond in writing, the Department may remove the plant

from the Program. If removed from the Program, the Producer may request to have the plant

reinstated once corrective actions have been taken.

8. Roadway Sampling - Producer's Roadway Quality Control (RC) samples are used to

check the quality of the in-place material on a project. These samples may be taken by the

Producer or Contractor from any lot of material. They will primarily be taken to provide

additional information concerning the quality of a lot of material for which the Quality Control

samples at the plant did not meet the specification requirements or from a sub lot of material that

has been corrected on the roadway. The minimum sample size for RC samples is 70 pounds.

B. NCDOT Verification and QA Split Sampling

The Department's Verification and QA Split samples are used to verify the performance of the

Producer's quality control plan.

Aggregate Sample Weight Requirements (pounds)

Material QC/QA Split Verification

Clean Coarse Aggregate 40 20

Fine Aggregate 20 10

Aggregate Base Material 70 35

1. Verification Samples- Verification samples will be taken independent of the Producer’s QC

samples and will be sampled from each size of material shipped. Producers will be allowed to

split the sample or take a sample adjacent to the Verification Sample for their internal

informational purposes only. This Producer’s sample will not be used as the next QC sample nor

will it be entered into the Department’s database.

2. QA Split Samples- QA Split samples will be taken and split for testing by both the Department

and the Producer for each size of material shipped. The Department’s representative will direct

the sampling and splitting process in accordance with Exhibits C and D respectively. The

Producer’s half of the QA Split is recorded as the next QC sample for that product.

3. Lot Size – A Verification sample will be taken for every 10,000 tons for each size of material

shipped or every two weeks, whichever occurs more often. QA Split samples for all aggregates

will be 20,000 tons for each size of material shipped, or at least once per quarter. All Verification

and QA Split sampling will be performed or observed by the Department’s representative.

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4. Sampling – The Department’s representative is to obtain samples taken from the stockpile,

conveyor belt or other location approved by the Department. Stockpile samples are to be taken

from the same area of the stockpile from which material is being shipped (load face).

5. Sample Identification and Record Keeping – It is critical that care be taken to properly label

samples and record test data accurately.

The Verification samples are to be numbered in a sequential order at the beginning of each year

or the first sample after a Producer’s facility is accepted into the program. The number following

“V” is the number for the independent sample, V-1, V-2, etc.

The QA Split samples are to be numbered with a number corresponding to the appropriate

Quality Control sample. The number following "QA" is the number of the corresponding Quality

Control split sample, QA-1, QA-2, etc.

6. Test Procedures – All Verification and QA Split samples are to be tested at a Department

laboratory. Modifications to standard test procedures are permitted in some cases in this program.

When approved by the Department on a site-by-site basis, a Producer may rapid dry ABC Quality

Control samples according to procedures outlined in Exhibit E. For ABC samples, soil mortar

testing is required on all samples, see Exhibit M.

Atterberg Limits (LL and PI) are not required to be performed on the Producer's half of the split

sample, except for those plants identified by the Department as having potential problems. In

those cases, the Producer is to determine the Atterberg Limits of one sample per 6,000 tons of

material. Rapid drying will not be permitted for material from which the Atterberg Limits are

determined.

7. QC/Verification Comparison – QC versus Verification samples will be compared using the f-test

and t-test (F&T) data compiled by QAP. The data will be checked in accordance with “Optimal

Procedures for Quality Assurance Specifications” FHWA-RD-02-095 (Appendix F). A report

will be generated quarterly to compare the data for any discrepancies within the program.

An investigation can be initiated when a minimum of one sieve is out of specifications, but will

be required when the F&T test indicates a single product has non-comparing means on two

sieves for clean stone or three sieves for ABC or fine aggregate (not including soil mortar). The

written investigation will be used to identify if there is any evidence that the populations are

different or determine if poor quality material is being produced. The investigation may include

lab assessment, technician assessments, and review of all test results.

If it is determined that the conditions are not being met, a warning letter to the Producer will be

issued and a nine month probation period will be implemented for the specified product(s). If

within the probation period, the F&T tests show non-comparing means and the written

investigation indicates poor quality material, the Producer’s specified product(s) may be removed

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from the program until corrective action has been taken and the specified product(s) have been

reinstated by the Department.

8. QC/QA Split Comparison – QC versus QA Split samples will be compared using the Paired t-

test based on the data provided in QAP. The data will be checked in accordance with “evaluation

of Procedures for Quality Assurance Specifications” FHWA-HRT-04-046. A report will be

generated quarterly to compare the data for any discrepancies within the program.

If the results of the QA Split sample are not in agreement with the results of the corresponding

Quality Control sample, i.e. outside the limits of Table I or Table II of Exhibit G, an investigation

will be made to determine the source of the difference. The investigation will include a review

of the testing procedures and the testing equipment. The results of the investigation will be

recorded in the Materials Inspector’s Comment Field in the Department’s computerized tracking

system (HiCAMS) and a copy given to the aggregate producer.

If the cause is determined to be improper splitting or testing procedures, the appropriate certified

technician will be notified. If the problem continues, the technician's certification may be

revoked. If the cause is determined to be in the Producer's testing equipment or handling of the

material the Producer is to take corrective action. If this problem continues, the Producer's

approval to provide material to the Department may be revoked. If the cause is determined to be

in the Department's testing equipment, the Department will take corrective action and notify the

aggregate producer of the action.

9. Noncompliance–The Department will notify the producer of the deficiencies and corrective

actions necessary to remain in the program. If the Producer does not respond in writing, the

Department may remove the plant from the Program. If removed from the Program, the Producer

may request to have the plant reinstated once corrective action has been taken.

C. Roadway Assurance/Acceptance and Independent Assurance

Roadway Assurance/Acceptance – Roadway Assurance (RA) samples are required to be taken

in accordance with the current NCDOT Minimum Sampling Guide. Lot sizes, sampling

procedures, acceptance limits, and other information related to RA Samples are described in the

current NCDOT Aggregate Sampling Manual.

Independent Assurance - NCDOT Independent Assurance (IA) samples are required on all

Federal-Aid projects. They are used to verify the performance of the Department's acceptance

program to the FHWA.

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GLOSSARY

Department Certified Laboratory- Any Department laboratory that has been certified for the

purpose of testing aggregates. (Verification and QA Splits)

Department Representative- Any person(s) employed by the Department or individual(s) under

contract with the Department for the purpose of sampling or inspecting aggregate production.

F-Test and t-Test- Statistical analysis used to compare the Verification samples with the Quality

Control Samples. (=.05)

Lot Size- Specified amount of material produced to be tested for approval. Tonnages are

specified in the NCDOT Minimum Sampling Guide.

NCDOT- North Carolina Department of Transportation.

The Department- North Carolina Department of Transportation or any other state agency.

NCDOT Right of Way- Any boundary of land maintained by the state of North Carolina

Paired-t Test- Used to compare means on a specific size of aggregate or other material over time

or in differing circumstances for QC/QA Split samples.

Plant Ownership Update Form- Document in Exhibit A that is updated yearly and required by

December 31st of each year.

Producer- An approved person or organization that produces aggregates to be sold and used by

the Department.

Producer’s Certified Laboratory- Any laboratory that has been certified by the Department for

the purpose of testing aggregates. The laboratory may be on site or off site with prior approval.

(Quality Control)

QA Split Sample- A sample that is taken under the direction of the Department Representative

by the QC Technician and split for testing by both the quarry and the Department. This sample

will be entered into HICAMS. QAP (Quality Assurance Program)- This system is intended to collect and analyze quality control and

quality assurance data for the aggregate and asphalt industries that do business with NCDOT.

Quality Assurance- Procedural activity implemented in a quality system so that requirements

and goals for a product are met. It is also used as a comparison with a standard for the specific

material to monitor the process that is set in place.

Quality Control- Process in which the Producer monitors the quality of their material being

shipped by taking random samples and conducting in house testing. This process will be tracked

in the QAP System.

Quality Control Plan- A document developed by the Producer proposing how they will control

equipment, materials, and production methods to insure that specified products are obtained.

Quality Control Technician- Any individual that has completed the NCDOT Aggregate QC/QA

Sampling Technician or NCDOT Aggregate QC/QA Sampling and Testing Technician

Certification course provided by the Department.

Verification Sample- A random and independent sample taken by a Representative of the

Department for the purpose of verifying the Quality Control results.

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IV. EXHIBITS

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EXHIBIT A- NCDOT AGGREGATE QC/QA PLANT OWNERSHIP UPDATE FORM

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EXHIBIT B- TESTING EQUIPMENT LIST

List of Equipment Required for Certified Laboratory testing Coarse or Fine Aggregate

1) Automatic shaker(s) for coarse and fine aggregate (with clock timer, enclosed in

insulated cabinet and mounted independent of building floor).

2) One set of electronic scales, readability and sensitivity of 0.1 gram, accurate to 0.1 gram

or 0.1 percent of capacity with a minimum capacity of 2500 grams.

3) One set of electronic scales, readability and sensitivity of 20 grams, accurate to 20 grams

or 0.1 percent of capacity with a minimum capacity of 50 kilograms (110 lbs).

4) A sufficient quantity of pans (24” x 12” x 3”) for drying samples.

5) One divider (8” x 14” x -3/4” opening) with two catch pans and one pouring pan.

6) One divider (chute width 24” and adjustable 1/2” bars).

7) One automatic shaker with timer, cover and all sieve sizes required to test ABC and

clean aggregates according to NCDOT Specifications.

8) Minimum of one set of 8” diameter sieves for testing ABC and one set of sieves for clean

stone and fine aggregate. Must have all sieve sizes required to test ABC fines and clean

aggregates according to NCDOT Specifications.

9) One mortar bowl (210 mm outside diameter).

10) One pestle (with 2” diameter rubber covered base or drill press with rubber disc).

11) One wooden mallet (1 3/4” x 3 1/2” x 6” with 1” diameter x 12 dowel centered).

12) A sufficient quantity of sample cans (approximately 400 gram capacity)and/or sample

pans.

13) One liquid limit machine (with grooving tool), AASHTO T-89. (Required if identified

as a source with potential plasticity issues)

14) One oven, gas or electric (thermostatically controlled @ 110C).

One oven thermometer (0 degrees to 150 degrees C)

15) A sufficient quantity of 2 oz. moisture cans.

16) One stiff blade spatula (3 1/2” x 13/16”).

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17) A sufficient quantity of evaporation dishes, 250 ml.

18) One dispersing machine and cup with ribs (3 extra blades).

19) One pair of tongs.

20) Dispersing agent.

*Check label. This should be free of bath oils beads.

List of Equipment Required for Certified Laboratory ONLY testing Fine Aggregate

1) One automatic shaker for fine aggregate (with clock timer, enclosed in insulated

cabinet and mounted independent of building floor).

2) One set of scales, readability and sensitivity of 0.1 gram, accurate to 0.1 gram or 0.1

percent of capacity with a minimum capacity of 2500 grams.

3) A sufficient quantity of pans for drying samples, and if used for AASHTO TP-33, must

be of sufficient size to contain the funnel stand and to prevent loss of material.

4) One divider (8” x 14” x -3/4” opening) with two catch pans and one pouring pan.

5) Minimum of one set of 8” diameter sieves for testing fine aggregate. Must have all sieve

sizes required to test according to NCDOT Specifications.

6) One oven, gas or electric (thermostatically controlled @ 110C). One oven thermometer

(0 degrees to 150 degrees C)

7) Sieve brushes.

8) Dispersing agent.

*Check label. This should be free of bath oils beads.

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EXHIBIT C- SAMPLING PROCEDURES

Sampling Procedures

I. Introduction

In order to reduce the number of variables that affect the correlation between, it is important that

all samples be obtained following procedures in accordance with this manual.

II. Production Stockpile Sampling

For stockpile sampling, obtain the sample from an area that represents material being shipped.

Before sampling, a visual inspection of the stockpile load face shall be conducted. If there is

evidence of segregation or contamination, immediate corrective action must be taken. The

material in question should be thoroughly mixed or removed before obtaining a sample. The

sample shall be obtained from aggregate that has been picked up by a loading unit from the

existing stockpile. The material from which the samples are to be obtained should be

approximately one loader bucket load. The loading unit shall dump the material on the ground

(as if loading a truck), then strike off and level to approximately half the original pile height. The

flat surface shall be divided into four sections. Identify sampling areas as A, B, C, and D, as

shown below. Opposite quadrants, such as A and D, shall be used to acquire the sample.

Material first dumped on ground Material after being leveled

off and sectioned

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The sample shall be obtained using a square point shovel having the long edges turned up at right

angles to the body of the shovel.

The shovel dimensions shall be: a standard squared end shovel with the outer edges rolled up

approximately 2 inches, such that the overall dimensions of the shovel are approximately 11”

long, 6” wide, with 2” sides. (See photo above)

III. Approved Stockpile Sampling

The lot size will be 2,000 tons of material, or a fraction thereof, placed in a stockpile. The

certified plant technician is to obtain a Quality Control (QC) sample weighing a minimum of 35

pounds

The sample shall be obtained by removing the top six inches (1/4 layer) of the layer and sampling

the underlying twelve inches (1/2 layer) of material using a steel sampling ring approved by the

Department. This will leave an undisturbed six inches (1/4 layer) on the bottom of the layer.

Samples taken after a layer has been corrected should be taken in the same manner as the original

sample with the exception that the sample shall be taken from the entire depth of the layer,

including the corrective material.

IV. Roadway Sampling

Roadway Sampling is described in the current NCDOT Aggregate Sampling Manual. Roadway

Acceptance samples shall not exceed limits of Column C Table I-2.

V. Belt Sampling

A sampling lot shall be represented by obtaining three randomly located samples from

approximately equal increments. The three samples are to be combined and tested. The sample

shall be taken from the conveyor belt before the material has passed through the pug mill, if a

pug mill is being utilized.

The sample is obtained by isolating a cross section of the belt and removing all material inside of

the isolated cross section. Samples obtained from a conveyor belt anywhere other than an

approved QC/QA Aggregate facility shall not exceed limits of Column C in Table I-2.

VI. Tube Sampling

Fine aggregate samples may be obtained from the stockpile using a tube approved by the

Department. The tube shall be a minimum of 1¼” (30mm) in diameter by 6 feet (2m) in length.

The tube shall be constructed of aluminum or PVC.

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The sample is obtained by inserting the tube into the stockpile at evenly spaced locations across

the load face of the pile. A minimum of five insertions of the tube shall be made. The insertions

are to be made at a minimum height of three feet from the bottom of the pile.

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EXHIBIT D- PROCEDURES FOR SPLITTING AND LABELING SAMPLES

Procedures for Splitting Samples using a Splitter

Samples are to be split using one of the two following procedures:

I. Place half of the material (i.e. approximately 35 pounds of a 70 pound sample) in the top

of the splitter. Open the splitter slowly, allowing the material to flow into the two catch pans.

Switch the pans from one side of the splitter to the other and place the remainder of the material

in the top of the splitter. Open the splitter slowly, allowing the remainder of the material to flow

into the two catch pans.

or

II. Place all of the material in the top of the splitter. Open the splitter slowly, allowing the

material to flow into the two catch pans. Compare the weights of the two pans to see if they are

within 3% of each other (i.e. within 2.1 pounds for a 70 pound sample). If they are not within

this tolerance, place all of the material back in the top of the splitter and repeat the procedure.

In both cases, the finger gate settings should be 1 1/2 times larger than the material being split,

the area on which the splitter rests should be level, and the material should be split before the

material is completely dry.

Procedures for Splitting Fine Aggregate Samples using a Divider

This procedure may be used in place of the splitter method described above for Fine Aggregate

samples only. The procedure requires the use of an impervious surface such as a steel plate, and

a four way divider. If a table is used, it shall be approximately 28 inches deep by 32 inches wide.

The four way divider shall have legs approximately 28 inches long that intersect in the middle,

forming a right angle. The device shall be approximately 5 inches tall. The material should be

split before the material is completely dry.

Place all of the moist material in the center of the table. Remix the sample thoroughly and

mound it in a cone shaped pile approximately 6 inches high. Push the four way divider down

through the center of the pile until contact with the table surface is made. Slide the divider back

and forth on the table surface to separate the fine aggregate sections from each other slightly.

Remove two of the opposite quadrants (sections) of material. Remix the remaining two

quadrants and repeat the procedure as necessary until the remaining material is the correct

quantity for the test to be run.

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Divider for Splitting Fine Aggregate Samples

14”

14”

Device is approximately 5” tall.

Device has four legs attached at right angles, each leg is 14” long.

Construction is of 18 gauge or similar aluminum.

Sample Numbering and Identification

Each size or type of material will have its own series of consecutive sample numbers beginning

with the number 1 for the first sample taken at the beginning of the calendar year. For example,

beginning January 1 the number sequences for each of the following products taken from the

same plant is as follows:

Quality Control Sample Identification

Product (size) Sample Number Sequence beginning January 1

#57 QC-1, QC-2, QC-3, QC-4, etc.

#67 QC-1, QC-2, QC-3, etc.

#78M QC-1, QC-2, QC-3, QC-4, etc.

Washed

Screenings

QC-1, QC-2, etc.

*QA Split samples will follow the corresponding QC sample sequence.

Verification Sample Identification

Product (size) Sample Number Sequence beginning January 1

#57 V-1, V-2, V-3, V-4, etc.

#67 V-1, V-2, V-3, etc.

#78M V-1, V-2, V-3, V-4, etc.

Washed

Screenings

V-1, V-2, etc.

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Producer’s QC Sample Card

M&T

PRODUCER’S QUALITY SAMPLE

QUARRY ________________________________ DOT LAB # _______________________________

PRODUCER ______________________________ QUARRY # ______________________________

SIZE MATERIAL _________________________ SAMPLE # ______________________________

DATE SAMPLED __________________ COUNTY __________________ COUNTY # __________

QUANTITY REPRESENTED BY THIS SAMPLE _________________________________________

SAMPLED BY: _______________________________________________________________________

SUBMITTED BY: _____________________________________________________________________

TYPE SAMPLE:

QUALITY CONTROL VERIFICATION

To be printed on 3 1/2” x 5 1/2” card stock

Each sample should be clearly identified by a properly filled out Sample Identification Card,

similar to the one shown above.

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EXHIBIT E- RAPID DRYING PROCEDURE

Rapid Drying Procedure

A. Use metal frame (angle iron) to support standard drying pans a minimum of 4" above gas

burner units or electric heating elements.

B. Sample size 30-40 pounds per pan (uniformly spread in pan)

C. For gas drying, adjust flame from burner units to avoid excessive heat directly to bottom of

pan.

D. During drying of sample, technician should be present at all times to:

1) Monitor and adjust heat when necessary,

2) Mix, stir and turn the aggregate over in the pan to prevent scorching of the sample.

E. Allow sample to cool, stirring sample occasionally to assist in uniform cooling.

F. Process the cooled sample.

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EXHIBIT F- QAP SYSTEM FOR REPORTING SAMPLE TEST DATA AND RETRIEVING

STATISTICS

The NCDOT Quality Assurance Program (QAP) is a web based Quality Control/Quality

Assurance application (available at https://apps.dot.state.nc.us/vendor/qap) used by both the

Department and material Producers/Suppliers who provide Aggregate or Asphalt materials to the

Department for highway construction projects. The system provides web enabled data entry of

individual QC & QA test results, secure file transfer of test results, access to individual and

summary test reports, and statistical analysis tools.

QAP Getting Started Guide Website:

https://connect.ncdot.gov/resources/Materials/MaterialsResources/QAP%20Getting%20Started%

20Guide.pdf

Each Producer/Supplier and applicable staff must be registered within the NCID system in order

to access results.

What QAP allows users to do:

Enter Aggregate QC and QA Test Results

Upload Aggregate QC and QA Test Results

Correct Aggregate QC and QA Test Results

View Aggregate Test Reports

Producers/Suppliers have editing abilities for QC samples only. QA data will be available to the

Producer once QC data has been entered and uploaded.

QAP Information Systems Liaison Contact Number: (919) 329-4200

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QAP/HiCAMS User Registration Form

The following information is required to link each Quality Assurance Program (QAP) user’s

NCID with the HiCAMS application. Please fill out this form completely and return it to your

company’s QAP Account Administrator.

COMPANY INFORMATION

Business Name

Business Address

Contact Phone Number

USER INFORMATION

Last 4 Digits of SSN

Last Name

First Name

Middle Name/Initial

Job Title

User ID from NCID

Email Address Linked to NCID Account

Supervisor’s Name

Supervisor’s Title

For Use by Company Account Administrator Only

Account Administrator Name

Administrator NCID User ID

I hereby confirm that I am a designated Account Administrator for the above company and do

authorize the above person to have access to my company’s information available via the

NCDOT QAP Application. I also verify the accuracy of the above user information.

Signed:

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List of Material Names for HiCAMS QC/QA Batch Process in QAP

Aggregate, Course – English

Material Description Code Name

Course Aggregate, #14M CA14M

Course Aggregate, #4 CA4

Course Aggregate, #467M CA467M

Course Aggregate, #5 CA5

Course Aggregate, #5 (VA Spec) CA5VA

Course Aggregate, #57 CA57

Course Aggregate, #57M CA57M

Course Aggregate, #6 CA6

Course Aggregate, #67 CA67

Course Aggregate, #68 (VA Spec) CA68VA

Course Aggregate, #7 CA7

Course Aggregate, #78M CA78M

Course Aggregate, # 8 (VA Spec) CA8VA

Aggregate Base Course – English

Material Description Code Name

Aggregate Base Course ABC

Aggregate Base Course, Modified ABCM

Aggregate Base Course, S-Gradation ABCSG

Stabilizer Aggregate SA

Aggregate, Fine – Asphalt – English

Material Description Code Name

Asphalt Sand AS

Baghouse Fines BF

Screenings, Dry SD

Screenings, Super-Washed SSW

Screenings, Washed SW

Aggregate, Fine – Concrete – English

Material Description Code Name

Sand, 1S S1S

Sand, 2MS S2MS

Sand, 2S S2S

Sand, 4S S4S

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North Carolina

Department of Transportation - Materials and Tests Unit

Raleigh, North Carolina

Producer’s Coarse Aggregate Quality Control Test Summary

Quarry: _____________________ Number: ___________ Producer: __________________________ Page: ______________

County: _____________________ Number: ___________ Size Material: ______

Grading - Percent Passing

Date Sample

Number

Quantity

(Tons)

2” 1.5” 1” 3/4” 1/2” 3/8” #4 #8 #10 #40 200+ #40

@

200

@

L.L. PI Note:

Sample

Fails

Who

Ran

+Place * in column if minus #200 is not run but is based on visual inspection. @ Soil mortar fraction for ABC.

Remarks:

cc: M&T Inspector _________________________________

M&T Files Quality Control Technician

Gradation Test Report Form

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EXHIBIT G- TOLERANCES FOR COMPARISONS OF QC/QA GRADATIONS

Table 1- Tolerances for Comparisons of Coarse Aggregate QC/QA Gradations Sieve Sizes

ABC* #4 #467M #5 #57

#57M

#6 #14M #67 VA#5 VA#68 #7 VA#8 #78M

HiCAMS

Size

CA4 CA467

M

CA5 CA57

CA57M

CA6 CA14

M

CA67 CA5VA CA68VA CA7 CA8VA CA78M

2"

1 1/2" ± 2 ± 2 ± 2 ± 2

1" ± 4 ± 4 ± 2 ± 3 ± 2 ± 2 ± 2

3/4" ± 4 ± 5 ± 5 ± 3 ± 3 ± 5 ± 3 ± 2 ± 2 ± 2

1/2" ± 5 ± 2 ± 5 ± 4 ± 2 ± 3 ± 3 ± 3

3/8" ± 2 ± 3 ± 2 ± 4 ± 3 ± 5 ± 2 ± 5 ± 3 ± 3 ± 3

#4 ± 6 ± 2 ± 3 ± 2 ± 5 ± 3 ± 3 ± 5 ± 5 ± 5

#8 ± 3 ± 5 ± 3 ± 3 ± 3 ± 3 ± 3

#10 ± 5

#16 ± 2 ± 2

#40 ± 5

#80

#200 ± 3 ± 0.5 ± 0.5 ± 0.5 ± 0.5 ± 0.5 ± 0.5 ± 0.5 ± 0.5 ± 0.5 ± 0.5 ± 0.5 ± 0.5

Soil Mortar

#40 ± 6

#200 ± 5

LL ± 4

*Use ABC range for all base course materials such as: ABC, ABC Type A, ABC Type B, ABC-M, ABC-S, CTB, CTBC, SA, etc.

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Table 2

Tolerances for Comparisons of Fine Aggregate QC/QA Gradations

Sieve Sizes Asphalt Sand,

SD, SW, SSW*

1S 2S 2MS 4S Super

Washed

Screenings

HiCAMS

Size

AS, SD, SW,

SSW

S1S S2S S2MS S4S SSW

1/2"

3/8"

#4 ± 2 ± 2

#8 ± 6 ± 1 ± 1 ± 1 ± 2 ± 6

#10 ± 6 ± 6

#16 ± 6 ± 3 ± 3 ± 3 ± 3 ± 6

#30 ± 6 ± 3 ± 3 ± 3 ± 3 ± 6

#40 ± 6 ± 6

#50 ±4 ± 2 ± 2 ± 2 ± 3 ±4

#100 ± 2 ± 1 ± 1 ± 1 ± 2 ± 2

#200 ± 2 ± 1 ± 1 ± 1 ± 1 ± 2 *DS- Dry Screenings, WS-Washed Screenings, SWS- Super Washed Screenings

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EXHIBIT H- INDEPENDENT ASSURANCE SAMPLING AND TESTING

Independent Assurance Sampling and Testing

I. Introduction

As discussed in Section IV-C, Independent Assurance (IA) samples are required on all Federal-

Aid projects. They are used to verify the performance of the Department’s acceptance program

to the FHWA.

II. Lot Sizes and Sampling Procedures

The lot size for ABC (Type A or B) and Cement Treated Base is 20,000 tons or a fraction thereof

For Type A ABC, Type B ABC, or road-mixed CTB, the IA sample for a lot will consist of one

sample, weighing a minimum of 70 pounds, taken from a location adjacent to the Roadway

Assurance sample. For plant-mixed CTB, the sample will be taken from the belt of the pug mill

immediately following the Roadway Assurance sample.

The gradation results of these samples will be correlated according to the procedures outlined in

the statistical program for comparing Independent Assurance test results and acceptance test

results. If the correlation results in a fair or poor rating, the Independent Assurance Section

Supervisor will conduct an investigation as to the cause of the rating.

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EXHIBIT I - SPECIFICATIONS (GRADATIONS, LL, and PI)

Stabilizer Aggregate (SA)

TABLE I-1

AGGREGATE BASE COURSE FOR STABILIZATION

GRADATION ACCEPTANCE CRITERIA

Sieve Size % Passing

l 1/2" 100

1" 72-100

1/2" 51-83

No. 4 35-60

No. 10 20-50

No. 40 10-34

No. 200 3-13

Material Passing No. 40 Sieve

L. L. 0-30

P. I. 0-6

Producer’s Quality Control Sampling

Plant Sampling:

The lot size for SA will be 2,000 tons of material, or a fraction thereof, shipped. The certified

plant technician is to obtain a Quality Control (QC) sample, weighing a minimum of 35 pounds.

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TABLE I-2

AGGREGATE BASE COURSE FOR

ABC, ABC-Type A, CTBC, Select Material Class IV

GRADATION ACCEPTANCE RANGES

Column A

Column B

% Passing

Column C

% Passing

1 1/2"

100

98-100

1"

75-97

72-100

1/2"

55-80

51-83

# 4

35-55

35-60

# 10

25-45

20-50

# 40

14-30

10-34

# 200

4-12

3-13

Material Passing No. 10 Sieve (Soil Mortar)

*# 40

40-84

36-86

*# 200

11-35

10-36

Material Passing No. 40 Sieve

L. L. 0-30 0-30

P. I. 0-4 0-4

* For information only, unless PI exceeds 4. If PI exceeds 4, soil mortar limits

apply. If PI exceeds 6, material shall be rejected.

Producer’s Quality Control Sampling

Plant Sampling:

The lot size for ABC will be 2,000 tons of material, or a fraction thereof, shipped. The certified

plant technician is to obtain a Quality Control (QC) sample, weighing a minimum of 35 pounds.

Roadway Correction:

When the Contractor chooses the option to correct the sublot, the Contractor will take 2 random

Roadway Quality Control Samples from within the corrected sub lot. When the test results of the

Contractor’s two Roadway Samples fall within the limits as shown in Column B of Table I-2, the

corrected sub lot will be acceptable for Quality Assurance Sampling by the Department.

The Contractor shall correct a QC lot on the roadway only once.

Base Material (ABC, ABC-Type A, CTBC, Class IV Select Material)

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The following flowchart summarizes the Roadway procedures when sampling and testing Type

A ABC.

Take 1 sample from

production stockpile, based on

material-specific rules

Sample

Meet

LL and PI?

Lot is rejected

and

replaced

NO

YES

Sample

Meet

Column C

NO

YES

Sample

Meet

Column B

NO

YES

RA Investigation is

performed by

Materials and

Tests

Representative

Meets Specifications

Meets Specifications

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Cement Treated Base Course (CTBC)

Producer’s Quality Control Sampling

Plant Sampling:

The lot size for aggregate base material for Cement Treated Base Course (CTBC) will be 2,000

tons of material, or a fraction thereof, shipped. The certified plant technician is to obtain a

Quality Control (QC) sample weighing a minimum of 35 pounds from each lot of CTBC.

Samples must be obtained using procedures outlined in Exhibit C and all samples must be taken

prior to the addition of cement. Each sample is to be clearly identified. If a split sample is

obtained, the other half of the sample will be retained and made available to the Department.

Rejections and Corrections:

If the Quality Control sample exceeds the limits shown in Column B of Table I-2, follow check

sample procedures described in Section III of this manual. Samples obtained from a conveyor

belt anywhere other than an approved QC/QA Aggregate facility shall not exceed limits of

Column C in Table I-2. Once cement has been added to the material a check sample cannot be

taken. The lot represented by the sample exceeding limits of Table I-2 will be rejected and shall

be removed and replaced by the Contractor at no cost to the Department.

The material passing the No. 40 sieve shall not have a Liquid Limit in excess of 30 or a plasticity

index in excess of 4. If any test result indicates values exceeding these, the lot will be rejected

and shall be removed and replaced by the Contractor.

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EXHIBIT J- PROJECT CONSTRUCTION OF APPROVED STOCKPILES (ABC- TYPE B)

Approved Stockpiles (ABC-Type B, Project Specific Stockpiles)

The following flowchart summarizes the QC procedures when sampling and testing Type B

ABC.

(Approved Stockpiles are stockpiles that are constructed for a specific project.)

Notification of Intent to Construct an Approved Stockpile

The Producer will submit to the State Materials Engineer a notification of intent to construct an

Approved Stockpile at least one month prior to the anticipated start date for construction of the

pile. The notification shall include the location of the pile, dimensions, total anticipated

tonnage, source of material, construction schedule, intended project (including location, Resident

Engineer, NCDOT Project Numbers, etc.), anticipated project quantities (pile quantity is not to

exceed 10% of the estimated quantity required for the project), contractor, and contact

information for all responsible producer and contractor personnel. The Producer shall notify the

State GeoMaterials Engineer at the completion of each layer and provide test results for approval

Take 1 sample from

sampling unit of

stockpile

Sample

Meet

LL and PI?

Lot is rejected and

replaced

NO

YES

Lot accepted, record

test results

Sample

meet

Column B

NO

YES

Lot is rejected and replaced or

corrected. Lot is retested after

corrective action is taken

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prior to the next layer being added. Continue this process until the pile has been built to

completion.

Construction

1. The area on which the stockpile is to be constructed shall be reasonably level and free

from stumps, wood, trash, loose earth, or other deleterious materials before

stockpiling begins.

2. The material shall be stockpiled in layers not exceeding two feet in thickness. Each

layer shall be constructed of sub-layers which shall not exceed 8 inches in thickness.

Each sub-layer shall be spread and/or mixed so that segregated spots and variability

are eliminated prior to placing the next sub-layer.

3. Material placed in the stockpile shall be uniform and “spot” additions of corrective

material will not be permitted unless it is shown that such methods produce a

uniform, non-segregated material.

4. Stockpiles shall be designated numerically (1, 2, 3, etc.) to ensure proper records of

sampling, testing, etc.

5. In order to facilitate construction, a stockpile may be constructed in sections which

shall be designated alphabetically (A, B, C, etc.). The limits of each section shall be

identified by properly maintained corner stakes as the work proceeds in order to

expedite construction of the remaining layers.

6. Each layer shall be spread and thoroughly mixed prior to sampling. No further

mixing shall be done after sampling.

7. A stockpile shall contain a minimum of 5 layers or 10 feet in height before approval is

given. The layers shall be set back at the edges at least 6 inches so that no roll-down

of material occur.

8. The material shall contain approximately optimum moisture when placed in the

stockpile. No sample shall be taken unless this condition is met.

9. Stockpiles shall exist separately and not connected to other stockpiles. Ramps used

by equipment in constructing the stockpile shall be removed upon completion of the

stockpile.

10. The top of a completed stockpile which is not to be used immediately shall be

approximately level and shall contain a berm around the top edges at least 18 inches

high to prevent wash down from rain.

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Producer’s Quality Control Sampling

The lot size will be 2,000 tons of material, or a fraction thereof, placed in a stockpile. The

certified plant technician is to obtain a Quality Control (QC) sample weighing a minimum of 35

pounds. Sampling will be performed as described in Exhibit B, Section III.

Table J-1

Type B Aggregate Base Course

Acceptance Criteria for Completed Stockpiles

Column A Column B

% Passing

1 1/2” 100

1” 76-96

1/2” 58-76

#4 38-52

#10 28-42

#40 16-28

#200 5-11

Material Passing No. 10 Sieve (Soil Mortar)

*#40 40-84

*#200 12-34

Material Passing No. 40 Sieve

L.L. 0-30

P.I. 0-4

* For information only, unless PI exceeds 4. If PI exceeds 4, soil mortar limits

apply. If PI exceeds 6, material shall be rejected.

If the Quality Control sample does not meet the gradation requirements of Column B of Table I-

2, or the LL and PI requirements of Column B of Table I-2, the procedures are as follows:

Correct the lot by either removing the material from the stockpile or by spreading the required

amount of corrective material over the surface of the lot. Only one correction of a lot will be

permitted and correction will not be allowed when the amount of material required exceeds 6

inches in depth, in which case the lot will be rejected and removed.

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NCDOT Quality Assurance Sampling

All QA samples are to be tested at a Department laboratory.

All QA samples will be sampled by the Producer with the Department representative present one

QA sample shall be obtained for each 8,000 tons of material stockpiled or per visit to the

approved stockpile, whichever occurs more often.

Stockpile Approval

The Producer will submit to the State GeoMaterials Engineer a request for approval of the pile.

The request shall include the location of the pile, dimensions, total tonnage, project (including

location, Resident Engineer, NCDOT Project Numbers, etc.), and gradation summary (showing

all individual QC Samples for the stockpile and the overall average gradation for the stockpile).

In the event of three consecutive roadway assurance sample failures, the Department may

withdraw the approval of the pile and will be sampled, tested, and accepted based on Exhibit I of

this manual.

If the individual QC Samples meet the requirements of Column B of Table I-2 and the average of

all QC Samples for the stockpile meet the requirements of Column B of Table J-1, the completed

stockpile will be considered acceptable.

No additional material may be placed on a stockpile after it has been completed and approved.

No material may be hauled from the stockpile until it has been approved.

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EXHIBIT K- INVESTIGATION PROCEDURES FOR FAILING ROADWAY ASSURANCE

SAMPLES

Procedures for Failing Roadway Assurance Samples

Take 1 sample from in-place

material on project, based on

material-specific rules

Sample

Meet

LL and PI?

NO

Lot is accepted

Record test results

YES

Lot is accepted

Record test results

Lot is rejected and may be corrected if

approved or removed and replaced. The

final decision regarding acceptance will

include results and conclusions from

investigation conducted when check sample

was taken. Resident Engineer will write

letter of explanation.

YES

Sample

meet

Column

C

NO

YES

Lot is rejected.

Check sample

obtained by

Geomaterials Lab.

Check

sample meet

LL and PI

NO

YES

NO Sample

meet

Column

C

Sample

Meet

LL and PI?

If lot is corrected

Take 1 sample from in-place

material on project, based on

material-specific rules

Sample

meet

Column

B

YES Lot is rejected

NO

NO

YES Lot is accepted

Record test results

Lot is rejected

and replaced

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EXHIBIT L- FIELD PROCEDURE FOR INVESTIGATION OF ROADWAY ASSURANCE

FAILURE FOR GEOMATERIALS FIELD ENGINEER

Procedure for Investigation of RA Failure for GeoMaterials Field Engineer

1) The State GeoMaterials Engineer notifies the Geomaterials Field Engineer that a roadway

sample has failed.

2) The Field Engineer contacts the Resident Engineer for the project to arrange obtaining a check

sample within 5 feet of the original sample location. The Department has the right to sample

beyond the 5 feet original sample location if any conditions listed in 5 and/or 7 are present or any

other extenuating circumstances that may influence the sample.

3) The Field Engineer contacts the Roadway Construction Engineer for that Division, and a

representative from the quarry supplying the ABC in question, to schedule a meeting on the

project to investigate the failure. At this time, the quarry technicians may take a check sample

adjacent to the Department’s check sample for their information only.

4) Before any check sampling takes place, the ABC soil reports from the Department Laboratory

are reviewed along with QC and QA to determine any trends or irregularities. Data will be

obtained from the previous three months of sampling for comparison.

5) The Field Engineer also interviews the ABC sampling technician to meet on the project if

possible to discuss and confirm that he or she is certified to take ABC samples and that the

proper sampling procedures were followed in the original sampling of the ABC. Items that will

be reviewed include:

using random numbers to determine sample location

staying 2 feet away from edges of spread when sampling

using the ABC steel sampling ring

sampling completely through to the next layer of material

making sure the quantity of the sample meets the 70 lbs. dry weight requirement

was the mechanical spreader being utilized in the area in question

could the sample have been taken on a seam where 2 lanes get blended together

potentially leading to segregation

noting any observations from the ABC sampling technician or other project

inspectors that may be pertinent to the investigation

6) After consideration of the above information, a check sample will be taken in accordance with

the current version of the Aggregate Sampling Manual and delivered to the Materials and Tests-

GeoMaterials Laboratory following standard sample submittal practice.

7) Other considerations will be made if:

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it is impossible to sample within 5 feet of the original sample due to location

(material covered, in a taper, unknown location of original sample)

the dump and push method was used in a tapered area

tailgated material was not sampled using the alternate method in accordance with

Appendix E of the Aggregate Sampling Manual

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EXHIBIT M AGGREGATE QC/QA SAMPLING AND TESTING TRAINING MANUAL

Test Procedures for Clean Coarse Aggregate and Fine Aggregate

Perform all aggregate sampling and testing in accordance with current specifications and

procedures referenced in the NCDOT Standard Specifications for Roads and Structures,

Aggregate Sampling (Roadway) and procedures outlined in this manual.

Aggregate for Concrete

Hydraulic cement concrete is a mixture of cement and water paste in which aggregate particles

are embedded. Aggregate is granular material such as sand, gravel, crushed stone, and blast-

furnace slag that usually occupies about 75 percent of the concrete’s volume. Besides reducing

volume changes due to drying shrinkage of the cement-water paste, aggregates are economical

filler that reduces the cost of concrete. Aggregate properties significantly affect the workability

of plastic concrete and also affect the durability, strength, thermal properties, and unit weight of

hardened concrete.

Aggregate for Asphalt Mixes

Most of the material in an asphalt concrete mixture is aggregates. The aggregates contribute

strength and stability to the completed pavement system. All of the particles needed in the

aggregate that will meet specifications and do the job usually cannot be found in a single

material; therefore, it becomes necessary to blend different sizes and materials in the proper

quantities to produce the desired gradation.

In order to accomplish this blending process correctly, it becomes extremely important that the

materials to be blended be properly sampled and the gradation or sieve size be accurately

determined.

1. Test Procedures - Clean Coarse Aggregate

The sample is obtained from a stockpile, conveyor belt, or any other location approved by the

Department according to established procedures and taken to the laboratory. When sampling

Clean Coarse Aggregate, follow the sampling procedures listed in Exhibit C.

Each sample should be clearly identified by a properly filled out Sample Identification Card,

(Exhibit D).

If the sample is to be split with half to be made available to the Department use the procedures

for splitting a sample (using a splitter) listed in Exhibit D.

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The split half of the Quality Control (QC) Sample, when approved by the Department on a site-

by-site basis, may be force dried as long as care and judgment are taken to avoid overheating.

When rapid drying a sample, follow procedures listed in Exhibit E.

Coarse aggregate will be tested for gradation in accordance with AASHTO T 27 procedures and

the wash test will be performed in accordance with AASHTO T 11.

Washed Gradation Procedures - Clean Coarse Aggregate (AASHTO T 11)

Test Procedures:

1. Once the sample is dried to a constant mass it is allowed to cool to the touch

prior to proceeding with any testing procedures.

2. Split sample until a workable size of 1,000 to 2,000 grams is obtained. Follow

procedures for splitting a sample described in Exhibit D.

3. Weigh and record weight of sample (Total dry Wt.).

4. Place sample in a container and cover with water to assure a thorough

separation of material finer than the No. 200 sieve form the coarser particles.

5. Using a large spoon vigorously agitate contents within the container.

6. Immediately pour the wash water over a nest of sieves that are arranged with

the coarser sieve on top.

7. Care should be used to avoid pouring the coarse particles out of the container.

8. Add water as previously described and repeat the procedures.

9. Repeat this process until the wash water is clear.

10. All material retained on the nested sieves shall be returned to the washed

sample.

11. The washed aggregate shall be dried to a constant mass at a temperature of

110 o C (+/- 5

o C) [230

o F (+/- 9

o F)]. If using the Rapid Dry method follow the

procedures in Exhibit E.

12. Weigh and record weight of the sample (Wt. after washing).

13. Calculate the percent passing the No. 200 sieve.

Calculation (formula):

Percent Passing No. 200 Sieve = (Total dry Wt. – Wt. after washing) x 100 Total dry Wt.

Example:

Assumption - a washed gradation test is performed on a sample of 57M material

Total dry Wt. = 1,520 grams Wt. after washing = 1,515 grams

Percent Passing No. 200 Sieve = (1,520 – 1,515) x 100 1,520

Percent Passing No. 200 Sieve = 0.3 % Passing

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Sieve Size Percent Passing Specification (Percent Passing)

# 200 0.3 0 – 1.0 Note: This sample meets Specifications for 57M passing the No. 200 Sieve for material that is tested from a

stockpile at the quarry site.

Sieve Analysis Procedures - Clean Coarse Aggregate (AASHTO T 27)

Test Procedures:

1. Once the sample is dried to a constant mass it is allowed to cool to the touch prior to

proceeding with any testing procedures.

2. Based on the Specifications for the material being tested, the proper sieves are selected.

Additional sieve(s) may be added as needed to determine Fineness Modulus or to prevent

sieve overloading.

3. The sieves are placed into the mechanical shaker with the smallest opening on bottom and

largest opening on top.

4. Weigh and record the weight of the sample.

5. Place the sample in the mechanical shaker and agitate for 10 minutes.

6. Carefully remove each sieve, weigh and record the retained material (cumulatively) using the

following steps:

a. Remove the top sieve weigh and record material retained

b. Remove the next sieve from the shaker and add the retained material to the material

from the first sieve.

c. Record cumulative weight from both sieves

d. Remove the next sieve from the shaker and add the retained material to the material

from the two previous sieves.

e. Record cumulative weight from all three sieves

f. Repeat this process for each of the remaining sieves to the catch pan.

7. Calculate the cumulative percent retained for each sieve

8. Calculate the percent passing for each sieve.

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Example of Calculating Percent Passing:

Assume a sieve analysis is performed on the 57M sample that was previously tested to determine

the percent passing the No. 200 sieve (using the wash gradation test). Based on the test results,

0.3 percent passed the No. 200 sieve. The total weight of the (dry) sample used for the sieve

analysis is 34.1 lbs.

Step 1 - Determine Cumulative Percent Retained for each sieve:

Cumulative Percent Retained = Cumulative Wt. retained x 100 Total dry Wt. of sample

Example of 1” Sieve

Cumulative percent retained = 1.4 x 100 = 4 % retained

34.1

Sieve

Size

Cumulative

lbs Retained

Cumulative

Percent Retained

1 ½” 0 0

1” 1.4 4

½” 25.9 80

#4 32.1 94

#8 33.5 98

Pan 34.1 100

Step 2 - Determine Percent Passing for each sieve:

Percent Passing = 100 – Cumulative Percent Retained

Example of 1” Sieve

100 – 4 = 96 % passing

Sieve

Size

Cumulative

lbs Retained

Cumulative

Percent

Retained

Percent

Passing

Specs

57M

1 ½” 0 0 100 100

1” 1.4 4 96 95-100

½” 25.9 80 20 25-45

#4 32.1 94 6 0-10

#8 33.5 98 2 0-5

Pan 34.1 100 0

Note: ½“ sieve exceeds Specifications

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Sieve Analysis – Clean Coarse Aggregate Work Problem 1

Check the following sieve analysis of a sample to determine if it meets the minimum

specification requirements for a # 67 stone. This sample was taken at a Ready Mix Concrete

Plant. Circle any sieves, if any, which exceed the minimum specifications.

Total weight of sample (oven-dried) = 35.6 lbs

Sieve

Size

Cumulative

Lbs. Retained

Cumulative

% Retained

Percent

Passing

NCDOT Specs.

(% Passing)

1 ” 0 100

¾ “ 2.8 90 – 100

½ “ 18.0

3/8 “ 27.4 20 – 55

#4 33.8 0 – 10

#8 35.0 0 – 5

Pan 35.6

Passing #200 (wash method)

#200 0.9 0 – 1.5

Does this sample meet the minimum Specifications for # 67 stone? ________________

Note: The ½“ sieve is not a standard size for # 67 stone. The information is needed for use in

design and control of plant mix asphalt.

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Sieve Analysis - Clean Coarse Aggregate Work Problem 2

Check the following sieve analysis of a sample to determine if it meets the minimum

specification requirements for a # 57 stone. This sample was taken at the quarry during

production. Circle any sieves, if any, which exceed the minimum specifications.

Total weight of sample (oven-dried) = 36.1 lbs

Sieve

Size

Cumulative

lbs. Retained

Cumulative

% Retained

Percent

Passing

NCDOT Specs.

(% Passing)

1 ½ ” 0 100

1 “ 1.1 90 – 100

½ “ 19.8 25 – 60

#4 34.1 0 – 10

#8 35.2 0 – 5

Pan 36.1

Passing #200 (wash method)

#200 0.5 0 – 0.6

Does this sample meet the minimum Specifications for # 57 stone? ________________

Test Procedures - Fine Aggregate

The sample is obtained from a stockpile, conveyor belt, or any other location approved by the

Department according to established procedures and taken to the laboratory. When sampling

Fine Aggregate, follow the sampling procedures listed in Exhibit D.

Each sample should be clearly identified by a properly filled out Sample Identification Card,

(Exhibit C).

If the sample is to be split with half to be made available to the Department use the procedures

for splitting a sample (using a splitter) listed in Exhibit D.

The split half of the Quality Control (QC) Sample, when approved by the Department on a site-

by-site basis, may be force dried as long as care and judgment are taken to avoid overheating.

When rapid drying a sample, follow procedures listed in Exhibit E.

Fine Aggregate will be tested for gradation in accordance with AASHTO T 27 procedures and

the wash test will be performed in accordance with AASHTO T 11.

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Washed Gradation Procedures - Fine Aggregate (AASHTO T 11)

Test Procedures:

1. Once the sample is dried to a constant mass it is allowed to cool to the touch

prior to proceeding with any testing procedures.

2. Split sample until a workable size of 400 to 600 grams is obtained (Note: this

sample size deviates from standard AASHTO procedures). Follow procedures for splitting a

sample described in Exhibit D.

3. Weigh and record weight of sample (Total dry Wt.).

4. Place sample in a container and cover with water to assure a thorough

separation of material finer than the No. 200 sieve form the coarser particles.

5. Using a large spoon vigorously agitate contents within the container.

6. Immediately pour the wash water over a nest of sieves that are arranged with

the coarser sieve on top.

7. Care should be used to avoid pouring the coarse particles out of the container.

8. Add water as previously described and repeat the procedures.

9. Repeat this process until the wash water is clear.

10. All material retained on the nested sieves shall be returned to the washed

sample.

11. The washed aggregate shall be dried to a constant mass at a temperature of

110 o C (+/- 5

o C) [230

o F (+/- 9

o F)]. If using the Rapid Dry method follow the

procedures in Exhibit D.

12. Weigh and record weight of the sample (Wt. after washing).

13. Calculate the percent passing the No. 200 sieve.

Calculation (formula):

Percent Passing No. 200 Sieve = (Total dry Wt. – Wt. after washing) x 100 Total dry Wt.

Example:

Assumption - a washed gradation test is performed on a sample of 2S sand

Total dry Wt. = 514.0 grams Wt. after washing = 504.9 grams

Percent Passing No. 200 Sieve = (514.0 – 504.9) x 100 514.0

Percent Passing No. 200 Sieve = (1.770) or 1.8 % Passing

Sieve Size Percent Passing Specification (Percent Passing)

# 200 1.8 0 – 3.0

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Sieve Analysis Procedures - Fine Aggregate (AASHTO T 27)

Test Procedures:

1. Once the sample is dried to a constant mass it is allowed to cool to the

touch prior to proceeding with any testing procedures.

2. Based on the Specifications for the material being tested, the proper sieves are selected.

Additional sieve(s) may be added as needed to determine Fineness Modulus or to prevent

sieve overloading.

3. The sieves are placed into the mechanical vibrator with the smallest opening on bottom and

largest opening on top.

4. Weigh and record the weight of the sample.

5. Place the sample in the mechanical shaker and agitate for 10 minutes.

6. Carefully weigh and record the retained material on each sieve (cumulatively) using the

following steps:

a. Carefully remove the nest of sieves from the shaker.

b. Remove the top sieve weigh and record material retained

c. Remove the next sieve and add the retained material to the material from the first

sieve.

d. Record cumulative weight from both sieves

e. Remove the next sieve and add the retained material to the material from the two

previous sieves.

f. Record cumulative weight from all three sieves

g. Repeat this process for each of the remaining sieves to the catch pan.

7. Verify mass of sample prior to sieving is within 0.3% of sample mass originally placed on

nest of sieves

8. Calculate the cumulative percent retained for each sieve.

9. Calculate the percent passing for each sieve.

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Example of Calculating Percent Passing:

Assume a sieve analysis is performed on the 2S sand sample that was previously tested to

determine the percent passing the No. 200 sieve (using the wash gradation test). Based on the

test results, 1.8 percent passed the No. 200 sieve. The total weight of the (dry) sample used for

the sieve analysis is 514.0 grams.

Step 1 - Determine the Cumulative Percent Retained for each sieve:

Cumulative Percent Retained = Cumulative Wt. retained x 100 Total dry Wt. of sample

Example of #4 Sieve

Cumulative percent retained = 15.4 x 100 = 3 % retained

514.0

Sieve

Size

Cumulative

gms Retained

Cumulative

Percent Retained

3/8 ” 0 0

#4 15.4 3

#8 51.4 10

#16 154.2 30

#30 257.6 50

#50 416.9 81

#100 488.3 95

Step 2 - Determine the Percent Passing for each sieve:

Percent Passing = 100 – Cumulative Percent Retained

Example of #4 Sieve

100 – 3 = 97 % passing

Sieve

Size

Cumulative

gms Retained

Cumulative

Percent Retained

Percent

Passing

Specs

2S

3/8 ” 0 0 100 100

#4 15.4 3 97 95-100

#8 51.4 10 90 80-100

#16 154.2 30 70 45-95

#30 257.6 50 50 25-75

#50 416.9 81 19 5-30

#100 488.3 95 5 0-10

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Sieve Analysis - Fine Aggregate Work Problem 1

Determine if the following sieve analysis of a sample meets the minimum specification

requirements for a 2MS sand. This sample was taken at the job site prior to use. Circle sieves, if

any, which exceed the minimum specifications.

Total weight of sample (oven-dried) = 547.9 grams

Weight of sample after washing #200 = 506.5 grams

Sieve

Size

Cumulative

gms Retained

Cumulative

% Retained

Percent

Passing

NCDOT

Specs.

(% Passing)

3/8 “ 0

#4 6.7 95 – 100

#8 68.8 80 – 100

#16 183.4 45 – 95

#30 355.3 25 – 75

#50 452.5 5 – 35

#100 503.9 0 - 20

Pan 506.5

Passing #200 (wash method)

#200 0 - 10

Does this sample meet the minimum Specifications for 2 MS sand? ________________

3. Fineness Modulus (F.M.)

Fineness Modulus is defined by the American Concrete Institute (ACI) as “an empirical factor

obtained by adding the total percentages (by weight) of an aggregate sample retained on each of

a specified series of sieves, and dividing the sum by 100”. Fineness Modulus (F.M.) is defined

mathematically as the sum of the cumulative percentage retained on the standard sieves divided

by 100. The Standard Size Sieves are 6”, 3”, 1 ½”, ¾”, 3/8”, No. 4, No. 8, No. 16, No 30, No.

50, and No. 100. It is an index to the fineness or coarseness of the aggregate. The F.M. is an

index of the fineness of the aggregate and should not be less than 2.3 or more than 3.1, nor vary

by more than 0.20 from batch to batch.

F.M. Rating Index Range

Coarse Sand 2.80 – 3.10

Medium Sand 2.50 – 2.80

Fine Sand 2.30 – 2.50

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(Note: When testing the gradation, the No. 200 sieve is used as required in the Specification.

However, it is not used in calculating the F.M. Do not include material retained in the Pan when

calculating the F.M.)

Fineness Modulus Example

Total weight of the sample (oven-dried before washing) = 514.8 grams

Oven dry weight (after washing #200) = 504.0 grams

Step 1 – Determine Cumulative Percent Retained for each sieve

Cumulative Percent Retained = Cumulative Wt. retained x 100 Total dry Wt. of sample

Sieve

Size

Cumulative

gms Retained

Cumulative

% Retained

3/8 “ 0 0

#4 15.1 3

#8 50.4 10

#16 119.9 23

#30 289.1 56

#50 434.2 84

#100 490.9 95

Pan 504.0

Step 2 – Determine the Fineness Modulus Index

The Fineness Modulus (F.M.) is defined mathematically as the sum of the cumulative

percentages retained on standard sieves divided by 100.

F.M. Index = (0 + 3 + 10 + 23 + 56 + 84 + 95) = 271 = 2.71

100 100

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Fineness Modulus Work Problem 1

Complete the following sieve analysis to determine if this sample of 2S material for use in

concrete meets minimum Specifications. This sample was taken at the job site prior to use.

Calculate the Fineness Modulus (F.M.) of this material.

Total weight of sample (oven-dried) = 573.0 grams

Weight of sample (after washing #200) = 557.4 grams

Sieve

Size

Cumulative

gms Retained

Cumulative

% Retained

Percent

Passing

NCDOT Specs.

(% Passing)

3/8 “ 0 100

#4 0 95 – 100

#8 22.9 80 - 100

#16 171.9 45 – 95

#30 286.5 25 – 75

#50 429.8 5 – 30

#100 521.4 0 – 10

Pan 557.4

Passing #200 (wash method)

#200 0 – 3

Determine the F.M. Index = _____________________________________________________

Based on the F.M. Index, this material is rated as a ___________ Sand.

A. Coarse

B. Medium

C. Fine

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AGGREGATE QC PROCESS- FLOW CHART

Take 1 sample from

production stockpile,

based on material-specific

rules

Sample

Pass?

Record test results NO

Record test results

YES Investigate the cause of

failure. Take corrective

action and record info.

Take check sample

Set aside half of sample for QA

testing at a Department facility

Sample

Pass?

NO

YES

Investigate the cause of

failure. Take corrective

action. Notify Department

Record test results and

reason why original sample

failed

Take second check

sample

Sample

Pass?

YES

NO

Notify Department. Stop

shipment of materials

used for Department only.

Work with Department to

investigate source of

failure and develop a

solution.

Resume regular

testing

procedures

Resume regular

testing procedures

Record test results

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CLEAN COARSE AGGREGATE AND FINE AGGREGATE QA PROCESS – FLOWCHART

The following flowchart summarizes the QA procedures for sampling and testing clean coarse

and fine aggregate.

Department Representative

visits quarry

Obtains, samples of products

that have been shipped to

the Department

Sample taken to Department

facility and tested

Sample

within

tolerance?

NO

YES

Record test results

Investigate until source of

difference is determined

Record results of

investigation on

Plant QA Form

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Example of QC Sampling

Scenario: Beginning the second week of January Hard Rock Quarry begins shipping 57M for the

first time this calendar year. This material is being shipped to a local concrete producer, asphalt

producer, and Department maintenance facility. Based on production and amount of material

ordered this material will be shipped for approximately the next 3 weeks. The following tables

summarize the tonnage shipped each day along with number of samples and sample numbering.

Week 1 of shipping 57M (for the calendar year)

Day Quantity Shipped Destination Samples Remarks

Monday 650 tons Concrete and

Asphalt

QC-1 First sample of

material for year

Tuesday 855 tons Concrete, Asphalt

and DOT

No sample

Wednesday 2,020 tons Concrete, Asphalt

and DOT

QC-2

Thursday 1,220 tons Concrete, Asphalt

and DOT

No sample

Friday 600 tons Concrete and

Asphalt

QC-3 Close out the week

During Week 1 of this scenario 5,345 tons of 57M was shipped. Based on the minimum

sampling frequency of one sample per 2,000 tons, 2.67 samples are required. In order to prevent

a possible shortage of samples we strongly recommend “closing out” each week. Therefore, for

this example, 3 samples are obtained and tested.

Week 2 of shipping 57M

Day Quantity Shipped Destination Samples Remarks

Monday 4,220 tons Concrete and

Asphalt

QC-3, QC-4

Tuesday 3,320 tons Concrete, Asphalt

and DOT

QC-5, QC-6

Wednesday 4,140 tons Concrete, Asphalt

and DOT

QC-7, QC-8

Thursday 2,125 tons Concrete, Asphalt

and DOT

QC-9

Total tonnage for week

13,805 tons

Friday 1,020 tons Concrete and

Asphalt

QC-10 Close out the week

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During Week 2 of this scenario 14,825 tons of material was shipped. Based on the minimum

sampling frequency of one sample per 2,000 tons, 7.41 samples are required. In order to prevent

a possible shortage of samples we strongly recommend “closing out” each week. Therefore, for

this example, 8 samples are obtained and tested.

Week 3 of shipping 57M

Day Quantity Shipped Destination Samples Remarks

Monday 0 tons No sample

Tuesday 100 tons DOT No sample

Wednesday 100 tons Concrete No sample

Thursday 40 tons DOT QC-11 1 sample per week

Friday 0 tons

QC-12 Split Sample (QA-12)

obtained when Department

representative visits plant

During Week 3 of this scenario 240 tons of material was shipped for the week. Though less than

2,000 tons of material was shipped this week a minimum of one sample is required if any

material is shipped. QC-12 obtained on Friday was required due to visit by a Department

representative.

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TEST PROCEDURES – AGGREGATE BASE PRODUCTS 1. Types of Aggregate Base Products

Aggregate Base Course (ABC) consists of a well-graded blend of fine and coarse aggregate

particles. When ABC is placed meeting the required specifications and compacted to the

minimum density requirements, it functions as an excellent foundation for the pavement

structure. The major structural function of an aggregate layer serving as a pavement base course

or sub-base is to distribute the stresses applied to the pavement surface from traffic loading.

Aggregate Base Course can provide sufficient strength and rutting resistance to maximize

bearing capacity and reduce rutting failure within the pavement layers. A quality ABC layer can

also provide additional benefits such as, controlling pumping, reducing frost action, improving

drainage of surface or subsurface water, controlling volume change in the subgrade when

expansive soils are present, and minimizing the lateral movement of the flexible pavement

system.

Cement Treated Base Course (CTBC) is an aggregate base material with the addition of

cement and is generally used on highways with high traffic volumes. CTBC offers the same

benefits as ABC; however, the addition of cement provides a higher strength or bearing capacity.

Aggregate Base Course (Modified) (ABC-M) is an aggregate base type product with a different

gradation specification when compared to ABC. ABC-M is generally used for maintenance

stabilization.

Stabilizer Aggregate (SA) is an aggregate base type product with a different specification

requirement when compared to ABC. SA is generally used on construction projects for subgrade

stabilization.

2. Types of ABC

Type A ABC – Production Pile. Type A ABC is ABC from a production pile. A production

pile can have new material added while existing material is being shipped to a customer.

Procedures for accepting material, taking roadway assurance check samples, correcting material,

applying penalties, and rejecting material are provided in Exhibit I.

Type B ABC – Approved Stockpile. Type B ABC is ABC that is used to build an Approved

Stockpile. An Approved Stockpile differs from a production pile in that specific procedures

must be followed as it is constructed. Additional information regarding Approved Stockpiles is

provided in Exhibits I and J.

When sampling aggregate base material, the sample is obtained from a stockpile, conveyor belt,

or any other location approved by the Department according to established procedures and taken

to the laboratory. When sampling aggregate base material, follow the sampling procedures listed

in Exhibit C.

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Each sample should be clearly identified by a properly filled out Sample Identification Card, see

Exhibit D.

Use the procedures for splitting a sample (using a splitter) listed in Exhibit D.

The Quality Control (QC) Sample, when approved by the Department on a site-by-site basis, may

be force dried as long as care and judgment are taken to avoid overheating. When rapid drying a

sample, follow procedures listed in Exhibit E. If the quarry is required by the Department to test

for Plasticity Index (P.I.) then the sample must be dried at a temperature not exceeding 60 o C or

140 o F.

3. Test Procedures – Aggregate Base Products

Sieve Analysis Procedures – Aggregate Base Products (AASHTO T 27)

Test Procedures:

1. Once the sample is dried to a constant mass it is allowed to cool to the

touch prior to proceeding with any testing procedures.

2. The 1 ½”, 1”, ¾”, ½”, 3/8”, #4 and #10 sieves are placed in the mechanical shaker with the

smallest openings on bottom and largest openings on top. A pan is placed in the shaker to

catch the -#10 material. The ¾” and 3/8” sieves are not necessary to determine gradation but

are inserted to prevent overloading other screens.

3. Weigh and record the weight of the sample.

4. Place the sample in the mechanical shaker and agitate for 10 minutes.

5. Carefully remove each sieve, weigh and record the retained material using the following

steps:

a. Weigh and record material retained on the 1 ½” sieve

b. Add retained material from the 1” sieve to the 1 ½” material.

c. Weigh and record the cumulative weight of material retained on 1” sieve

d. Add retained material from the ¾” sieve to the 1 ½” and 1” material.

e. Add retained material from the ½” sieve to the 1 ½”, 1”, and ¾” material

f. Weigh and record as the cumulative weight of material retained on the ½” sieve

g. Add retained material from the 3/8” sieve to the 1 ½”, 1”, ¾”, and ½” material.

h. Add retained material from the #4 sieve to the 1 ½”, 1”, ¾”, ½”, and 3/8” material

i. Weigh and record the cumulative weight of material retained on the #4 sieve.

j. Add retained material from the #10 sieve to the 1 ½”, 1”, ¾”, ½”, 3/8”, and #4 material

k. Weigh and record the cumulative weigh of material retained on the #10 sieve.

l. The - #10 material in the shaker pan is reduced by splitting to a sample size of

approximately 600 grams and placed in a sample can. This sample of - #10 material is used

to determine the percent passing the #40 and #200 sieves and, if required, the Liquid Limit

(L.L.) and Plasticity Index (P.I.).

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6. A representative sample (approximately 100 grams) of - #10 material is obtained and placed

in an evaporating dish (with approximately 250 ml. capacity). The remaining - #10 material

is set aside for determining Liquid Limit and Plasticity Index if required.

7. Add one teaspoon of dispersing agent (without bath beads) to the sample

8. Add sufficient water to cover the sample.

9. Gently stir mixture until the dispersing agent has dissolved and the sample is saturated.

10. Carefully place mixture into the dispersing cup and disperse for one minute (on low speed

setting).

11. Wash the sample over a #200 mesh sieve until the wash water is practically clear.

12. Dry the sample to a constant mass either by the rapid dry method as described in the Exhibit

E or by using an oven set at a temperature of 110 o C (+/- 5

o) or 230

o F (+/- 9

o).

13. Once the sample is dried it must be allowed to cool to the touch prior to performing any

additional tests.

14. Once cooled, the sample is placed in a mechanical shaker with a nest of sieves, including a

catch pan, and cover plate. The sieve sizes are as follows: #40, #100, and #200 (place sieves

with the largest openings on top and smallest on bottom). The #100 is included to prevent

overloading of the #200 sieve.

15. The sample is screened for 10 minutes in the mechanical shaker.

16. Weigh and record the material retained on the #40 sieve

17. Add the material retained on the #100 sieve to the material retained on the #40 sieve.

18. Add the material retained on #200 sieve to the #40 and #100 material.

19. Weigh and record the cumulative material from the #40, #100, and #200 sieve to determine

the cumulative weight retained on the #200 sieve.

20. Verify mass of sample (used for soil mortar) after sieving is within 0.3% of mass placed on

nest of sieves.

21. Calculate the cumulative percent retained on each sieve to the #10 sieve

22. Calculate the percent passing each sieve down to the #10 sieve

23. Calculate the cumulative percent retained on the #40 and #200 sieve (- #10 material or Soil

Mortar).

24. Calculate the percent passing on the #40 and #200 sieve.

25. Calculate the percent passing for each sieve (top to bottom) and complete the gradation

results

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Example of Calculating Percent Passing:

Assume this sieve analysis is performed on ABC. The total weight of the (dry) sample used for

the sieve analysis is 41.4 lbs.

Step 1 - Determine Cumulative Percent Retained for each sieve:

Cumulative Percent Retained = Cumulative Wt. retained x 100 Total dry Wt. of sample

Example of 1” Sieve Cumulative Percent Retained = 2.3 x 100 = 6 % retained

41.4

Sieve

Size

Cumulative

lbs Retained

Cumulative

Percent Retained

1 ½” 0 0

1” 2.3 6

½” 13.3 32

#4 23.7 57

#10 29.1 70

Pan

Assume this sieve analysis for the - #10 (Soil Mortar) material began with a dry weight of 100.0

grams

Step 2 - Determine Cumulative Percent Retained for the #40 and #200 sieves (- #10 material or

Soil Mortar):

Cumulative Percent Retained = Cumulative Wt. retained x 100 Total dry Wt. of sample

Example of #40 Sieve

Cumulative percent retained = 48 x 100 = 48 % retained

100.0

Sieve

Size

Cumulative

gms Retained

Cumulative

Percent Retained

#40 48 48

#200 71 71

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Step 3 - Determine Percent Passing for each sieve:

Percent Passing = 100 – Cumulative Percent Retained

Example of 1” Sieve

100 – 6 = 94 % passing

Sieve

Size

Cumulative

lbs Retained

Cumulative

Percent Retained

Percent

Passing

1 ½” 0 0 100

1” 2.3 6 94

½” 13.3 32 68

#4 23.7 57 43

#10 29.1 70 30

Example of #40 Sieve (Soil Mortar):

100 – 48 = 52 % passing

Sieve

Size

Cumulative

gms Retained

Cumulative

Percent Retained

Percent

Passing

#40 48 48 52

#200 71 71 29

Step 4 – Determine Percent Passing for each sieve (total sample):

Percent Passing Total Sample (#40) = Percent Passing #10 x Percent Passing #40 x 100

Example: % Passing #40 (total) = 0.30 x 0.52 x 100 = 15.6 or 16 % Passing

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Percent Passing Total Sample (#200) = Percent Passing #10 x Percent Passing #200 x 100

Example: % Passing #200 (total) = 0.30 x 0.29 x 100 = 8.7 or 9 % Passing

Sieve

Size

Percent

Passing

1 ½” 100

1” 94

½” 68

#4 43

#10 30

#40 16

#200 9

Soil Mortar

#40 52

#200 29

Sieve Analysis – ABC Work Problem 1

Assume the following results represent sample QC-20. Determine the percent passing for each

sieve (including Soil Mortar). The total weight of the sample is 82.3 lbs and a 100.0 gram

sample was used to test the soil mortar (#40 and #200 sieves).

Sieve

Size

Cumulative

lbs Retained

Cumulative

Percent Retained

Percent

Passing

1 ½” 0

1” 4.9

½” 28.0

#4 46.9

#10 55.1

#40 ------ ------

#200 ------ ------

Soil Mortar

#40 37.7 gms

#200 68.2 gms

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Sieve Analysis – ABC Work Problem 2

Assume the following results represent sample QC-21. Determine the percent passing for each

sieve (including Soil Mortar). The total weight of the sample is 81.1 lbs and a 105.0 gram

sample was used to test the soil mortar (#40 and #200 sieves).

Sieve

Size

Cumulative

lbs Retained

Cumulative

Percent Retained

Percent

Passing

1 ½” 0

1” 4.5

½” 27.8

#4 46.4

#10 54.8

#40 ------ ------

#200 ------ ------

Soil Mortar

#40 38.7 gms

#200 71.2 gms

Gradation Specifications – ABC Work Problem 1

Using the results from Work Problems 1 and 2 (QC-20 & QC-21), determine if any of the two

sampling lot exceeds Specifications for Gradation. Place a single asterisk if a Gradation

Specification. The Specifications are provided and are also listed in Table I-2 Exhibit I.

Sieve

Size

Percent

Passing

QC-20

Percent

Passing

QC-21

Gradation

Specs Column B

Gradation

Specs Column C

1 ½” 100 98 – 100

1” 75 – 97 72 – 100

½” 55 – 80 51 – 83

#4 35 – 55 35 – 60

#10 25 – 45 20 – 50

#40 14 – 30 10 – 34

#200 4 – 12 3 – 13

Soil Mortar

#40 40 – 84 36 – 86

#200 11 - 35 10 - 36

(*) - Gradation Specification exceeded

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Atterberg Limit (Liquid Limit and Plasticity Index) Procedures

If the quarry has been identified by the Department as having potential problems with Liquid

Limit (LL) or Plasticity Index (PI), the Atterberg Limits must be determined for each 6,000 tons

of material shipped. The Liquid Limit is defined as the moisture content at which a soil passes

from a plastic state to a liquid state and is determined by AASHTO T 89. The Plastic Limit is

defined as the moisture content at which a soil passes from a semisolid state to a plastic state and

is determined by AASHTO T 90. The Plasticity Index (PI) is the numerical difference between

the Liquid Limit and Plastic Limit (P.I. = L.L. – P.L.).

Obtaining - #40 Material

To determine the Atterberg Limits, use the remaining - #10 material that was set aside while

performing the sieve analysis (Step 5 k). Since the Liquid Limit and Plasticity Index are

determined on the - #40 material, the sample must be separated into two parts. This can be

accomplished by sieving the material over a #40 sieve and a catch pan. The fraction retained on

the #40 sieve shall be ground in a mortar with a rubber-covered pestle or suitable mechanical

device in such a manner as to break up the aggregation of material particles without fracturing

the individual grains. If the sample contains brittle fragments such as flakes of mica, fragment of

sea shell, etc., the grinding operation shall be done carefully and with just enough pressure to free

the fragments from adhering to particles of finer material. After grinding the sample, it is to be

re-sieved over the #40. The grinding and sieving process are repeated until the following

conditions are met:

Repeated grinding only produces a small amount of - #40 material

Rubbing the + #40 material between the thumb and forefinger indicates the

material is clean

Once clean, the remaining + #40 material is discarded. The - #40 material (in catch pan) is

thoroughly mixed and placed into a sample can. This sample will be used to determine the

Liquid Limit and Plasticity Index and should be clearly identified.

Inspection and adjustment of Atterberg (or Liquid Limit) Device

The Atterberg Device shall be inspected to determine that it is in good working order, that the pin

connecting the cup is not worn sufficiently to permit side play; that the screws connecting the cup

to the hanger arm are tight; and that a groove has not been worn in the cup through long usage.

The grooving tool shall be inspected to determine that the critical dimensions are as shown in

Figure1.

By means of the gauge on the handle of the grooving tool, and the adjustment plat H

Figure 1, the height to which the cup C is lifted shall be adjusted so that the point on the cup

which comes in contact with the base is exactly 1 cm (0.3937 in.) above base. To adjust for the

one centimeter lift, the strike point on the cup must be determined. To determine the strike point,

place carbon paper between the cup and rubber base and turn the handle several times to get a

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carbon mark on the bottom of the cup. Place a piece of scotch tape across the middle of the

carbon mark and slide the handle of the grooving tool until it touches the tape. The adjustment

plate H shall then be secured by tightening the screws, I. With the gauge still in place, the

adjustment shall be checked by revolving the crank rapidly several times. If the adjustment is

correct, a slight ringing sound will be heard when the cam strikes the cam follower. If the cup is

raised off the gauge or no sound is heard, further adjustment shall be made.

Figure 1 – Atterberg Device

Atterberg Device

Cup Assembly Base

Dimension A B C N K L M

Description Radius

of Cup

Thickness

of Cup

Depth

Of Cup

Cup at Cam

Follower

to Base

Thickness Length Width

Metric, mm 54 2.0 27 47 50 150 125

Tolerance,

mm 2 0.1 0 1.5 5 5 5

Grooving Tool

Curved End Gage

Dimension a b c d *e

Description Thickness

Cutting

Edge Width Depth Length

Metric, mm 10.0 2.0 13.5 10.0 15.9

Tolerance,

mm 0.1 0.1 0.1 0.2 ------

Note: Plate “H” may be designed for using (1) one securing screw (I).

An additional wear tolerance of 0.1 mm shall be allowed for dimension “b” for used grooving tools.

Feet for base shall be of resilient material.

(*) Nominal dimensions.

All tolerances specified are plus or minus (+/-) except as noted above.

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Liquid Limit Test Procedures (AASHTO T 89)

1. Verify the Atterberg Device is calibrated for a 1 centimeter drop of the brass cup.

2. Thoroughly mix and obtain 50 to 100 grams of the - #40 material and place it in an

evaporating dish.

3. Add water to the sample in the dish.

4. Mix the sample and water together with a spatula by stirring and kneading the sample.

5. If needed, continue adding water and mixing until the sample is near the Liquid Limit

(based on judgment and experience of person conducting test).

6. Using the spatula, place material in lower half of the brass cup using as few strokes as

possible (excess strokes will bring the water to the top of the sample).

7. Using the spatula strike off the sample to a depth of 1 centimeter in the cup.

8. Using the grooving tool, make a groove in the sample from the top to the bottom (verify

the sample and grooving tool blade are the same depth).

9. Attach the brass cup to the Atterberg Device.

10. Turn the crank 25 times at a rate of approximately 2 turns per second.

11. If the sample comes or flows together on the 25th

blow between ¼” to ½” in the cup then

the material is considered to be at its liquid limit. If this does not occur on the 25th

blow

then the sample will have to be dried or more water added to reach the liquid limit.

12. If repeating these steps to achieve the liquid limit, thoroughly clean and dry the grooving

tool and brass cup between each series.

13. If the requirements are met, use the spatula to obtain a slice of material which flowed

together by cutting at right angles to the groove from edge to edge (approximately 30

grams).

14. Place the sample into a moisture can or watch glass of known weight.

15. Weigh and record the weight of the sample.

16. Place the sample in an oven set at 110 o C (+/- 5

o) or 230

o F (+/- 9

o) for three hours or

until dry.

17. Carefully (Caution: Hot) remove sample from oven.

18. Place glass on top of container to determine if moisture is forming on the glass. If

moisture forms, place sample back in oven. Repeat this process until sample is dry.

19. If dry, allow sample to cool to room temperature.

20. Weigh and record weight

21. Calculate percent of moisture and record

22. Discard material

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Modified Liquid Limit Test

When the Liquid Limit test cannot be performed on non-plastic material with the Atterberg

Device due to slippage of the divided mass in the brass cup, the Liquid Limit shall be determined

in the following manner:

1. Thoroughly mix and obtain 50 to 100 grams of the - #40 material and place it in an

evaporating dish.

2. Add water to the sample in the dish.

3. Mix the sample and water together with a spatula by stirring and kneading the sample.

4. If needed, continue adding water and mixing until the sample is near the Liquid Limit

(based on judgment and experience of person conducting test).

5. Using the spatula spread the mass firmly in the evaporating dish.

6. Using a clean, dry spatula press the blade firmly on the surface of the mass.

7. Lift the blade without dragging.

8. Clean and dry the blade or use the other side and press the blade firmly in the same

location of the mass.

9. Lift the blade without dragging.

10. Verify if water beads appear on the side that was pressed in the mass.

11. If beads form and adhere to the spatula blade, the consistency of Liquid Limit has been

reached.

12. Obtain the sample from the location where the blade was pressed into the mass.

13. Place the sample into a moisture can or watch glass of known weight.

14. Weigh and record the weight of the sample.

15. Place the sample in an oven set at 110 o C (+/- 5

o) or 230

o F (+/- 9

o) for three hours or

until dry.

16. Carefully (Caution: Hot) remove sample from oven.

17. Place glass on top of container to determine if moisture is forming on the glass. If

moisture forms, place sample back in oven. Repeat this process until sample is dry.

18. If dry, allow sample to cool to room temperature.

19. Weigh and record weight.

20. Calculate percent of moisture and record.

21. Discard material.

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Plastic Limit Test Procedures (AASHTO T 90)

Since the moisture content for the Liquid Limit is higher than the Plastic Limit this procedure

will dry the sample back to the moisture content at which the material remains plastic.

1. Take the remaining material in the brass cup (from Liquid Limit test) and form it into a

ball (approximately 15 grams).

2. Break the ball into 4 approximately equal ellipsoidal masses and place each on unglazed

paper.

3. Using your fingers, roll each ellipsoidal mass individually (on the paper) out into a 1/8”

diameter thread. Use only minimal pressure with your fingers and roll at an angle.

4. Repeat the rolling process on the paper until the material crumbles before reaching a 1/8”

diameter thread.

5. Once the first piece is rolled down collect and set it to the side. Repeat this procedure

with each of the remaining (3) pieces (Steps 3 and 4). Note: Use clean paper for each

mass “roll-down”.

6. Re-roll the total sample into one ball with your fingertips.

7. Place the sample into a moisture can or watch glass of known weight.

8. Weigh and record the weight of the sample.

9. Place the sample in an oven set at 110 o C (+/- 5

o) or 230

o F (+/- 9

o) for three hours or

until dry.

10. Carefully (Caution: Hot) remove sample from oven.

11. Place glass on top of container to determine if moisture is forming on the glass. If

moisture forms, place sample back in oven. Repeat this process until sample is dry.

12. If dry, allow sample to cool to room temperature.

13. Weigh and record weight.

14. Calculate percent of moisture and record.

15. Discard material.

Formulas/Calculations - Liquid Limit, Plastic Limit, and Plasticity Index:

Liquid Limit (LL) = (Wt. cup and Wet Soil – Wt. cup and Oven Dry Soil) x 100 Wt. of Oven Dry Soil Plastic Limit (PL) = (Wt. Cup and Wet Soil – Wt. Cup and Oven Dry Soil) x 100 Wt. of Oven Dry Soil Plasticity Index (PI) = Liquid Limit – Plastic Limit

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Example of Liquid Limit, Plastic Limit, and Plasticity Index

Liquid Limit Results (Wt. in grams)

Wt. of

Cup

Wt. of Cup

& Wet Soil

Wt. of Cup &

Dry Soil

Wt. of Dry

Soil

Wt. of

Water

66.3 86.0 82.2 15.9 3.8

Liquid Limit (LL) = (86.0 – 82.2) x 100 = 23.8

15.9

Plastic Limit Results (Wt. in grams)

Wt. of

Cup

Wt. of Cup

& Wet Soil

Wt. of Cup &

Dry Soil

Wt. of Dry

Soil

Wt. of

Water

63.1 75.0 72.9 9.8 2.1

Plastic Limit (PL) = (75.0 – 72.9) x 100 = 21.4

9.8

Plasticity Index (PI) = 23.8 – 21.4 = 2.4

Based on the results of this example a Liquid Limit (LL) of 24 and a Plasticity Index (PI) of 2

would be reported.

Once the calculations are completed determine if the results exceed any of the Specifications for

Liquid Limit (LL) or Plasticity Index (PI) and record the results on the appropriate form.

Procedures for accepting material, taking roadway check samples, correcting material, applying

penalties and rejecting aggregate base material are provided in Exhibit I.

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AGGREGATE BASE COURSE PRODUCTS QA SPLIT SAMPLE PROCESS – FLOWCHART

The following flowchart summarizes the QA Split sample procedures when sampling and testing

an aggregate base type product. Refer to Exhibit F for tolerances between QC and QA test

results.

Department Representative

obtains split half of QC sample

and takes it to Department

Laboratory

QA and QC

test results

within

tolerances

Investigate source of

difference

NO

Record test results

YES

Notify the certified technician.

If problem continues,

certification may be revoked

NO

Accept material

YES

Reject material and perform

further investigation

Difference

between

test results

resolved

NO

Take another set of

QC/QA comparison

samples with

Department

representative

Problem with

sampling or

testing

procedures

YES

Problem

with

producer’s

equipment

Producer needs to take corrective

action. If problem continues,

producer’s approval to provide

material to the Department may

be revoked

NO

QA sample tested

QA and QC

test results

within

tolerances

Record results of the

investigation on Plant QA

Form

YES

YES

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SAMPLE SELECTION, NUMBERING AND IDENTIFICATION

A random selection process must be used when sampling base course material. Randomly

selecting a sample location prevents biased sampling and a simple procedure using random

numbers can accomplish this task. An example of computer generated numbers may be as

follows:

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CALCULATING RANDOM LOCATION TYPE A AND TYPE B ABC

Type A ABC Random Numbers Calculation

Each sampling lot is to be 2,000 tons.

The following example demonstrates how random numbers are used to determine the tonnage

where each sample is to be taken for Type A ABC:

Step 1 - Random numbers: 1234 (column numbers)

2952

4167

2730 (random numbers)

0560

2754

Step 2 - Calculate tonnage for the sample within the first 2,000 ton lot using a random number

from columns 1 and 2 above. In this example the number is 29. Place a decimal in front to get

the random number of 0.29 Multiply the random number by the tonnage as shown below:

2,000 tons x 0.29 = 580 tons (Pull the sample)

Step 3 – Strike a line through the random number 29 (do not use again). Go to the next random

number (52) when calculating the tonnage for the next sampling lot.

This process would be repeated for each sample.

Type B ABC Random Numbers Calculation

The following example demonstrates how random numbers are used to determine the location in

the stockpile where each sample is to be taken for Type B ABC:

Step 1 - Random numbers: 1234 (column numbers)

2952

4167

2730 (random numbers)

0560

2754

Since the sample will be taken from a Type B ABC stockpile, the width and length of the pile

will be used to determine sampling locations. For this example the pile is 200 feet in length and

100 feet in width.

Step 2 - Calculate the random length for the sample using a random number from columns 3 and

4 above. In this example the number is 52. Place a decimal in front to get the random number of

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0.52. Multiply the random number by the length of the pile (refer to the calculations below).

Determine a random width by using a random number from columns 1 and 2 above. In this

example the number is 41. Place a decimal in front to get the random number of 0.41. Multiply

the random number by the width of the pile (refer to the calculations below).

200 feet x 0.52 = 104 feet length

100 feet x 0.41 = 41 feet width

Step 3 – Measuring the calculated distances from a fixed reference point on the pile location the

point for the sample. Once a reference point is established it must remain the same until the pile

is approved by the Geomaterials Engineer.

Step 4 – Strike a line through the random numbers 52 and 41 (do not use again). Use the next

numbers in the sequence (67 and 27) when calculating the next sample location.

This process would be repeated for each layer of the stockpile until the pile is completed and

approved by the Geomaterials Engineer.

Random selection and numbering ABC samples – Example

Assume: A quarry has been awarded a contract to supply ABC for a construction project this year

and begins shipping March 15. This is the first ABC shipped for the calendar year. Based on the

number of trucks and location of the project the Contractor is projected to place approximately

2,000 to 3,000 tons per day. In addition to this project maintenance trucks of the Department are

obtaining ABC. Based on calculations the tonnage a sample is to be taken and the sample

number would be as follows:

Random Numbers: 1 2 3 4 (column number)

5 8 7 0

9 2 6 3

2 0 0 2

9 5 6 8

8 2 4 3 Day Tonnage

shipped

Tonnage

Shipped

cumulative

Based on random # the following samples would be

obtained (daily cumulative tonnage sample is taken)

Remarks

Monday 2,800 2,800 QC-1 (1160) QC-2 pulled on

Tuesday

Calculations: QC-1 = 2,000 tons x 0.58 = 1160 tons

QC-2 = 2,000 tons x 0.70 = 1400 tons + 2,000 tons = 3,400 tons (pull sample the

following day)

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Day Tonnage

shipped

Tonnage

Shipped

cumulative

Based on random # the following samples would be

obtained (daily cumulative tonnage sample is taken)

Remarks

Tuesday 2,900 5,700 QC-2 (3400) QC-3 pulled on

Wednesday

Calculations: QC-3 = 2,000 tons x 0.92 = 1840 tons + 4,000 = 5840 tons (pull sample the

following day)

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VI. References

Standard Specifications for Transportation Materials and Methods of Sampling and Testing, American

Association of State Highway and Transportation Officials

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EXHIBIT N QC/QA PROGRAM CONTACT INFORMATION

Chris Peoples, P.E.

State Materials Engineer

Materials and Tests Unit

1801 Blue Ridge Rd.

Raleigh, NC 27607

(919) 329-4000 (phone)

(919) 733-8742 (fax)

Website: https://connect.ncdot.gov/resources/Materials/Pages/default.aspx

Contact - information regarding the Program (i.e. getting on the Program, Physical Properties

List, Equipment Wavier, etc.)

Quality Assurance Engineer

Jessica Earley, P.E.

(919) 814-2220 (phone)

(919) 329-8494 (fax)

Contact - information regarding sampling or testing procedures and QC/QA Class scheduling

State GeoMaterials Engineer

Mehdi Haeri

(919) 329-4150 (phone)

(919) 733-8742 (fax)

[email protected] (email)

Contact – information regarding HiCAMS/QAP

Information Systems Liaison

Francine Ward

(919) 329-HELP (4357) (phone)

(919) 733-8742 (fax)

[email protected] (email)

Information regarding the QC/QA Aggregate Sampling and Testing Class Schedule can also be

found on the NCDOT Materials and Tests Unit website.

https://connect.ncdot.gov/resources/Materials/Pages/SoilsLaboratoryTrainingSchools.aspx